Apparatus for uniting metals



Nov. 29, 1927. 1,651,344

J. B. AUSTIN APPARATUS FOR UNITING METALS Original Filed Aug. 18, 1924 INVENTOR- ATTO EY Patented Nov. 29, 1927.

i UNITED STATES 1,651,344 PATENT OFFICE.

JOHN 13. AUSTIN, OF CLEVELAND, OHIO, ASSIGNOR TO UNA WELDING AND BONDING- COMPANY, OF CLEVELAND, OHIO, A CORPORATION OF DELAWARE.

APPARATUS FOR UNITING METALS.

Original application filed August 18, 1924, Serial No. 732,802. Divided and this application filed October 6, 1924, Serial No. 741,844.

My invention relates to the art of uniting nonferrous and ferrous metals. More particularly it relates to a new and improved process of uniting a copper bond to the base 6 and web of a steel railway rail. It also relates to a process of uniting copper to each of two or more adjacent steel surfaces disposed at angles to each other. It further relates to a new and improved apparatus 10 adapted to form about the copper portion of a copper bond a molten metal retaining wall adapted to cooperate with a railbase and web to retain molten metal in contact with the rail base and web and with the copper of the bond while the weld is being made.

Prior to my invention it was not the practice, so far as I am aware, to unite copper bonds directly to the web of a rail by a flame without seriously weakening a portion of the web, due to the melting of a portion thereof. Although it was desirable to attach mine bonds to the rail webs, because of the protection thus afforded the bond and because of the welding difficulties encountered in bonding to wet and rusty rail bases, it was considered unsafe to bond to the web of the rail by any bonding process employing a heating flame becauseof the fear of resulting serious injury to and weakening of the rail web.

I have discovered, however, that copper bonds can be directly welded to the web of a rail by means of a heating flame without any substantial melting of or noticeable injury to the rail. I have also discovered that a copper bond may be quickly and easily united by means of a heating flame to both the base and web of a wet or rusty rail.

Briefly stated, my improved process for practicing my discoveries comprises forming a molten metal retaining wall about a portion of the copper of a bond on a rail base, melting copper onto the rail base and retaining it by the said retaining wall and maintaining the copper in a molten condition until it has united with the rail base, rail web and the copper of the bond. A device suitable for practicing my invention may be described briefly as comprising a mold portion formed to cooperate with the rail base and web in providing walls to retain molten metal on the base of a rail adjacent to the rail web and thru one wall of Renewed July 19, 1927.

which a portion of the copper of the bond extends.

For the purpose of disclosing my invention to those skilled in the art, I have elected to describe hereinafter my new and improved process as practiced in uniting a copper bond to the base and web of a steel rail and have shown devices suitable for use in connection therewith, I do not wish to be understood, however, as limiting my invention to these specific disclosures since it will be obvious to those skilled in the art that my improved process and devices may be employed in attaching copper to two or more angularly dis osed steel surfaces and since various modi cations in the process, as well as the devices coming within the scope of my invention, will, no doubt, occur to others.

In the accompanying drawings forming a part of this specification Fig. 1 is a perspective view of a rail and bond, assembled with a mold portion embodying my invention.

Fig. 2 is top plan view of the mold portion of Fig. 1.

Fig. 3 is an end elevation on line 33 of Fig. 2.

Fig. 4 is a side elevation on line -i4 of Fig. 2, and

Fig. 5 is a fragmentary top plan view, partly in section, of a rail and a modified form of mold portion embodying my invention.

In Figs. 1 to 4 inclusive of the drawings numeral 1 designates a fragmentary part of a minerail with a bond 2 positioned adjacent to the base and web in position to be united to the rail base and web, and 3 indicates as an entirety, a device for forming with the base and web of the'rail a molten metal retaining mold cavity about the end 4: of the copper of the bond 2.

The device or mold portion 3 as shown in these figures seats on the rail base 1 and co operates therewith and with the rail web 1 to retain molten metal adjacent to the end of the end 1 of the bond 2 in position to unite therewith and with the base and web of the rail. It preferably consists of a bond positioning member 5, preferably composed of copper, adapted to rest on the base 1*, of the rail and substantially to engage with the web 1 of the rail, and having provided in its lower surface with a recess 6 of substantially the size and configuration of the end of the bond 2 for use therewith. A rib 7 acts as a stop against which a suitable flange or rib P on the bond may engage, thereby positioning a portion of the copper of the bond in the device 3 on the rail and preventing the escape of molten metal around this part of the casting cavity thus formed. Connected to member 5 is a mold cavity forming member 8, preferably composed of carbon and likewise adapted to rest on the base of the rail and to engage with the web of the rail. This member 5 is preferably cut away as at 8 to bound a portion of a mold cavity or recess 9, which is open to the recess 6 and other walls of which cavity are formed by the web and base of the rail, so as to retain molten metal in contact with the rail web and base and with the copper of the bond projecting thereinto. This mold cavity is preferably open at the top so that molten metal may be brought into the recess 9 through the top thereof and maintained molten therein by a heating flame directed thereinto. Other walls of the mold cavity or recess 9 are formed by the rail web and base when the mold portion 3 is in assembled position on to a rail base.

The members 5 and 8 may be connected together in any suitable manner. In this instance they are connected by a thin sheet metal band 10 which runs along one end and one side of member 8 and one end of member 5 and carries pins 11 which project into suitable openings 11 in the member 8 and also carries a screw 12 which engages with a tapped opening 12 in member 5. A pin 13 carried by member 5 and projecting into a recess 13 in the member 8 serves to position members 5 and 8 at their junction. Mold portion may be held in position on a rail by any suitable means, including a clamp or weight or even welding a metal part thereof to the rail.

In practicing my invention on a mine rail I first remove the mud and any other foreign material from the base of the rail, without, however, taking pains to dry the rail base or remove rust, except large particles which may be knocked off readily. Then I position a bond 2 with the outstanding rib 4r contacting with the rib 7 on the member 5. The bond 2 and mold portion 3 are then placed on the rail base adjacent to the rail web and retained in such position in any suitable manner. This may be done, for example, by means of a clamp or mold holder where said mold portion is detachably connected to the copper of the bond, and if it is a mold so secured to the copper bond head as to be substantially permanent therewith, that is, the mold portion is carried by the bond head and is made of metal, it may be welded or clamped to the rail as desired.

Copper may be melted by a suitable heating flame into the mold cavity and additional heat supplied to the copper by directing the flame on the molten copper of the rail without directing the flame on the steel and maintaining the flame thereon until the molten copper unites to a portion of the cop per of the bond and to the base and web of the rail. For this purpose any suitable heat ing flame may be used such as the electric are or gas flame, for example, oxy-acetylenc. With the electric arc either a. carbon or a metal electrode may be used. The union of the copper to the rail is denoted by the wetting of the rail by the copper. This wettin action is indicated by the formation of a concave meniscus by the copper adjacent to the rail.

While the above process may be carried out by melting pure copper into the mold cavity, it is preferable to employ with the copper a deoxidizing agent, such as silicon in amount of about 0.25%. By employing a deoxidizing agent, such as silicon, the process may be carried out in less time and probably at a lower temperature than when no deoxidizing agent is employed.

Successive increments of copper may be melted into the mold cavity from the cop per electrode and the arc maintained'on said molten copper until sufficient copper has been melted into said mold cavity and the I copper therein has united with a portion of the copper of the bond and with the base and web of the rail. The uniting of the copper to the steel will be indicated by the wetting of the steel by the copper. ploying as an electrode copper having a deoxidizing agent alloyed therewith, the said agent is melted in uniform relation to the copper and is distributed uniformly throughout the bath of molten copper. By the use of said deoxidizing reagent, this process may be carried out in less time and probably at a lower temperature than would be possible without the use of said reagent. It will be noted that in practicing my invention with the use of the metal are, employing a copper electrode, containing silicon, the uniting'of the copper to the steel is effected substantially simultaneously with the completion of the melting ,of the copper into the mold cavity.

It will be noted that if the rail is substantially dry and reasonably free from rust or similar substances, a clean, non-porous junction will be formed between the copper and substantially all the rail surface in contact therewith. If, however, the rail be wet or covered with a substantial coating of rust or similar substances, or both wet and covered with said substances as is often thecase in the mines, the portion of the rail base interiorly of the mold cavity may not be completely united with the copper throughout the contacting surfaces thereof, especially if the metal are process is employed. The

By em- I portion of the rail web interiorly of the mold cavity, however, will be united with the copper throughout substantially their contacting surfaces. It will be noted, however. that where the weld of the copper to the steel is principally disposed along the contacting surfaces of the copper and the web portion of the rail interiorly ot the mold, the area of welded contact is sufliciently large to provide suflicient mechanical strength and electrical conductivity. In the mines it is preferred to employ the metal arc in carrying out this process. In this case a copper rod may be used as an electrode. Preferably the deoxidizing agent is added simultaneously with the melting of the copper and thus there may be employed a copper electrode containing about 0.25% silicon distributed substantially uniformly therein.

In Figure 5 --l[ have shown a slightly different form of mold portion applied to the fragment of a rail, the sectioned part of the figure indicating the web after the head oi the rail has been removed. This mold portion 15 consists of a bond positioning member 16 preferably composed of copper having a recess 17 with a rib. 18 projecting therein to engage behind the rib 4 of the copper portion 4 of a bond end. This member 16 is adapted to reston the rail base 1*. At either end thereof I provide molten metal retaining wall members 19 which are pretcrably composed of carbon and which rest on the rail base and engage with the rail web as shown.

A sheet metal band 20 is bent to engage the top and outer sides of members 16 and 19 and carries screws 21 which secure these members in the assembled position shown in this figure.

When mold portion 15 rests on a rail base and against a rail web a molten metal re-- taining mold cavity 22 is formed, the rail base and web constituting certain walls thereof and the numbers 16, 19 and the copper of a bond comprising the remaining walls thereof. The mold portion is thus open at its top to receive molten metal and to permit a heating flame to be directed into molten metal in the mold cavity; and is open at its side and bottom to expose the rail web and base to contact with themolten metal.

It will be understood that under certain conditions the members 19 and 2t) may be entirely omitted, retaining only the member 16 to serve as a molten metal retainer in con-- junction with the rail base and web, so that the metal may be melted between this member 16 and the web of the rail in contact with the rail base. The mold portion 15 shown in this figure may be used in practicing my invention in substantially the same manner as has been previously described in connection with molds shown in Figs. 1 to a It will thus be seen that my process may be carried out without injury to the rail or any deleterious efl'ect upon the rail. As a matter of fact, a bond attached by my process does not injure the rail at the point of attachment of the bond and there is no gouging of the steel of the rail or creation of injurious eflects thereon or therein by the electric arc, there being no occasion for the arc to come into direct contact with the steel of the rail either on the base or on the web.

While l have shown and. described my process as applied to the uniting of a portion of the copper of a bond to the base and web of a rail I do not wish to be understood as limiting my invention to the process specifically thereto, but ll wish the scope of my invention to include the uniting of a nonferrous article to two angularly disposed surfaces of a ferrous article, and while for the sake of brevity the claims specify the word rail, ll intend such word to be comprehensive of any two angularly disposed non-ferrous surfaces, and the word copper in the claims to be comprehensive of any non-ferrous metal used for the purpose or conducting electricity.

Furthermore, it is to be understood that the particular form of apparatus shown and described, and the particular procedure set forth, are presented for purposes of explanation and illustration and that various modifications of said apparatusand procedure can be made without departing from my invention as defined in the appended claims.

This application is a division of my copending application, Serial No. 732,802, filed August 18, 1924.

What I claim is:

1. A mold portion for east welding copper to thebase and web of a rail, which comprises an upright wall adapted to extend along the base of the rail to the web thereof so as to term with said base and web an open top mold cavity into which a portion of the copper of a bond extends.

2. A mold portion for east welding copper to the base and web of a rail, which comprises an upright retaining wall adapted to ave extended through it a portion of the copper of a bond, said mold portion being adapted to rest on the rail so that the base and web of the rail together with said mold portion form an open top mold cavity to retain molten metal in contact with the base and web of a. rail and said portion of the copper of the bond extending into said mold cavity.

3. A mold portion for east welding copper to the base and web of a rail, which comprises an upright retaining wall adapted to have extended through it a portion of the copper oi a bond, said mold portion being adapted to rest on the rail so that the base and web of the rail together with said mold lllltl and web of the rail together with said mold portion form an open top mold cavity to retain molten metal in contact with the base and web of a rail, and said portion of the copper of the bond extending into said mold cavity and said retaining wall having inner walls formed of a refractory material.

5. A mold portion for cast welding copper to the base and web of a rail, which comprises an upright metal retaining wall havlng a refractory lining, said retaining wall beng adapted to extend along the base of the rail and to form with the said base and web an open'top mold cavity into which a portion of the copper of a bond extends.

6. A mold portion for east welding copper to the base and web of a rail, which comprises an upright metal retaining wall having a refractory lining, said retaining wall being adapted to extend along the base of the rail and. to form with said base and web an open top mold cavity into which a portion of the copper of a bond extends, said retaining wall having carried thereby a heat conductive member adjacent the portion of the copper of the bond.

7. A mold for use in uniting a copper bond to a steel rail base and web which comprises a copper member formed to seat on the base and engage the web of a rail and having 9.

bond positioning recess in its lower edge, a carbon member formed to seat on the base and engage the web of a rail and having an open top molten metal retaining recess open to the rail web and base and to the copper member adjacent the said recess therein.

8. A mold for use in uniting a copper bond to the base and web of a steel rail which comprises connect-ed bond positioning and molten metal retaining members, each formed to rest on a rail base and to engage a rail web, each member having a recess open to the rail base and web and the recess in the other member, the recess in the molten metal retaining member having an open top.

9. A mold for use in uniting a copper bond to the web and base of a railway rail which comprises a rail base and web engaging member suitably recessed to position a bond end adjacent to the base and web of a rail, a second base and web engaging member joining the first said member and suitably recessed to permit metal to be melted thereinto about a bond and positioned by the first said member and in engagement with a rail base and web.

10. A mold for railway bonds comprising two cooperating recessed members each formed to seat on a rail base and to engage the rail web, each recess in the said members being open to the rail base and web and to each other and one of the recesses being open at the top, one of the said members being adapted to position the end of a rail bond adjacent to the base and web and the other member bein adapted to retain molten metal about t%e end of the rail bond so positioned.

In testimony whereof I hereunto afiix my signature this 10th day of September, 1924.

JOHN B. AUSTIN. 

